Cladding panel

ABSTRACT

A panel for covering a substrate including: a body having a first connecting profile and a second connecting profile, and a mesh, the first connecting profile and the second connecting profile being complementarily shaped in such a way that adjacent panels are coupled to one another via the first connecting profile and the second connecting profile, each of the first connecting profile and the second connecting profile comprising a pocket and a flange, the pocket of the first connecting profile being shaped for receiving the flange of the second connecting profile and the pocket of the second connecting profile being shaped for receiving the flange of the first connecting profile, wherein the mesh overhangs both the pocket of the first connecting profile and the pocket of the second connecting profile, said mesh overhangs configured for attachment of the panel to the substrate.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.17/335,480, which in turn is a continuation of U.S. patent applicationSer. No. 16/473,883 filed Jun. 26, 2019, which in turn is a nationalstage application under 35 U.S.C. 371 of International Application No.PCT/CA2018/000015, filed Jan. 25, 2018, which in turn claims the benefitunder 35 U.S.C. 119(e) of U.S. Provisional Application No. 62/450,426,filed Jan. 25, 2017, the contents of each of which are herebyincorporated by reference into the present disclosure.

FIELD OF THE INVENTION

The field of this invention relates to cladding material constructionsand, more particular, to cladding panels and modules for decorationand/or insulation of structures such as buildings and houses.

BACKGROUND OF THE INVENTION

The most common materials, for insulate the walls and the roofs of ahouse, are rigid foam (polystyrene or polyurethane), or wool (made formfiberglass or rock). Those materials are typically light, with a highinsulation power (their R-value per inch is between 3.2 and 7.2).However, because of their softness and permeability, these materialsneed protection: this is why in a building they are found inside thewalls or in the attic. The insulation process is relatively easy toexecute during the construction of the building; unfortunately, theinsulation process may not be as easy for an already constructed housewith a solid bricks or stones finishing, which needs to improve itsinsulation.

A solution, in this case, is to insulate the exterior surface of thewall with rigid foam and then protecting it with vinyl siding or stucco(EIFS system) giving up at the aesthetic finishing of the existingfaçade. Another solution to protect the insulation and at the same timehave a similar finishing is building an additional wall in order tosupport the weight of the new installation (made of bricks or stones).

In the last decades, stone veneer became another alternative protectionand finishing of the insulation made of rigid foam installed on exteriorwall of the house. Made from concrete and colored with iron oxide, thisproduct is less heavy and easier to work with than real stone or brick;it can be installed, after a proper preparation, directly on the rigidinsulation and the appeal, look like real.

Another solution is using polyurethane panels (faux stone) with theappeal of bricks or stones assembled and grouted. This product,differently from the previously mentioned stone veneer, has insulationpower, albeit low due its high density in order to increase hismechanical resistance.

However, all the previously mentioned products and materials have stronglimitations:

Built on site EIFS System:

-   -   It can crack: 1. when is made manually on site, the thickness of        the coating is not even causing different shrinks; 2. when made        under extreme whether condition; 3. The system itself can hold        just some but not all of the natural movement of the building        being insulated; 4.

Because the exterior surface is permeable, the moister, trapped insidethe coating, will eventually turn in ice in the winter, and deterioratethe insulation property.

-   -   The color fades because of the UV effect    -   It can't hold any weight except with some precautions    -   Patches or additions will be always noticeable

Pre-fabricated system EIFS:

-   -   The exterior finishing, made in panels, shows seam where the        panels join    -   Variation of finishing just in the color

Stones end Brick:

-   -   Because of their weight, transportation and handling require        excessive time and is expensive    -   Brick absorbs moister causing crumbling over the years    -   Have to be installed and cut one by one    -   Experts to layer breaks are not easy to find    -   Stone quarries are not everywhere    -   not earthquake-proof

Stone veneer:

-   -   They can be installed directly on the rigid insulation, but        because of the weight of the stone veneer, the insulation board        surface needs to be reinforced adding to the cost and time of        labor    -   The color is superficial. If cut or accidentally chipped will        show the material of which are made: concrete    -   Because of its porosity, the concrete absorbs and transfers        moisture to the insulation    -   Not earthquake-proof

Polyurethane panels (faux stone)

-   -   The color is superficial. If cut or accidentally chipped will        show the material of which are made: polyurethane    -   Easy to scratch    -   Their look is poor (i.e. poor aesthetics)    -   Because are made in panels they need to be cut in order to get        the desired dimension in proximity of the corners, leaving a        visible straight vertical seam and a non-continuity in the        finishing.

Perhaps with the exception of the polyurethane panel, the othermaterials mentioned above require skilled labor.

Technical Problem

The demand of performance products capable to overcome the aboveproblems and limitations has prompted the industry of insulation systemand of artificial stones to develop system of insulation with newconcepts. The obstacle to overcome is represented by the need to give toa “soft” material, such as polystyrene or polyurethane, hardness, beautyand durability like the finest materials of marble or stone. U.S. Pat.No. 8,806,838 discloses a stone plate attached to a front surface of theinsulating board; and a reinforcing board attached to a rear surface ofthe insulating board where brackets will connect, said stone plate, saidinsulating board and said reinforcing board, to the wall. However, theabove technology has several limitations. A limit in the finishing,because of the absorption characteristic of the cement of which saidstone is made. A limit in the high cost of said reinforcing boardattached to a rear surface of the insulating board, and a limit in saidbrackets made in metal, that, connecting the three above said layers,will become a thermal bridge from the outside to the wall. On the otherhand, for the industry of said artificial stones, the obstacle is todevelop a product that may represent appearance close to the naturalbeauty of the marble, stones or bricks, and at the same time, lightenough to install it on an insulation board. For the obstacle of theappearance above mentioned, German Patent No 5364 672 discloses a methodto produce artificial stones using a mix of waste glass and resin. Thisprocedure, that includes the exclusive use of waste or new powder glass,will leave on the surface an unnatural color because the glass isartificially colored. Japanese Patent No 6127458 provides also anartificial stone molded by injecting a composition of resin and mineralchips into a mold and after cured and demolded, polished, in order toshow the minerals color. The limit on the result, appear on thepolishing phase, that will expose, unprotected, the surface of themineral, which can be affected by UV and the weather. Combining theweightlessness and the insulation characteristics of the foam materialwith those of decoration and stability of brick or stone is the biggestchallenge.

Technical Solution

Marble is a metamorphic rock composed of recrystallized carbonateminerals, most commonly calcite or dolomite. The recrystallizedcarbonate minerals are those that give the translucency feature to thisbeautiful stone called from the Ancient Greek (mármaros), “crystallinerock, shining stone”. The method of transfer durable features, such ashardness, shape, texture, translucency of the natural color of thestones, marble, bricks (terra cotta) on a soft insulating surface, tomake it as a unique product, its use and application, is the object ofthis patent. The present invention includes the creation of a system ofinsulation modules having the appearance of dry stack or grout stonesiding or grout brick or hollow tiles or roof tiles or any other shapes.The insulation system of the present invention includes a number ofmodules with substantial coordinated sizing under a criterion disclosedin this document.

Advantageous Effects

The present invention relates to panels with an external surface thatsimulates brick, stone, tile or marble and includes a method that mayprovide a kit of panels that, when installed on a surface includingwall, floor or roof, without a need to cut or modify, said modules willfit any sizes of said surfaces, without showing where said modules arejoining. Additionally includes methods to produce artificial claddingthat includes grout between components, including stones, bricks ortiles, assembled as one body in a module that may be part of said kit.Furthermore, include method to produce said grout in independent colorfrom the color of said components. Moreover includes methods to produceon said module, a controlled thickness of a layer of insulation in orderto determinate desired R-value.

SUMMARY OF THE INVENTION

In one embodiment, the present invention relates to a cladding panelcomprising a top multi-film layer and a base layer configured forconnection to a substrate, the top multi-film layer including at leastan external substantially transparent film and a granular film adjacentto the external substantially transparent film.

In one embodiment of the cladding panel of the present invention, thetop multi-film layer further includes a support film of background coloradjacent to the granular film.

In another embodiment of the cladding panel of the present invention,the cladding panel further comprises a middle layer connecting the topmulti-film layer to the base layer.

In another embodiment of the cladding panel of the present invention,the granular film is a composition comprising one or more additives ofan inorganic filler, a cross-linking agent, a cross-linking acceleratorand one or more color pigments.

In another embodiment of the cladding panel of the present invention,the granular film includes dust of a natural rock, including marble, andgranite.

In another embodiment of the cladding panel of the present invention,the base layer comprises an insulating material.

In another embodiment of the cladding panel of the present invention,the cladding panel includes sides having an attachment mechanism thatfrictionally interlocks with the attachment mechanism of anothercomplementary cladding panel.

In another embodiment of the cladding panel of the present invention,the base layer has sides with dovetail shapes for connection to anothercladding panel.

In another embodiment of the cladding panel of the present invention,the interior layer includes ventilation channels.

In another embodiment of the cladding panel of the present invention,the top multi-film layer is configured to simulate stones, tiles orbricks separated by grout.

In another embodiment, the present invention provides for a method ofmanufacturing a cladding panel for cladding a surface of a structure.The method, in one embodiment, comprises: (a) layering a substantiallytransparent polymer so as to form a substantially transparent film; and(b) disposing onto the substantially transparent film a layer of naturalgranules thereby forming a granular film, wherein the substantiallytransparent layer and the layer of natural granules form a multi-filmexternal layer of the cladding panel.

In one embodiment of the method of manufacturing a cladding panel of thepresent invention, the method further comprises: (c) disposing onto thegranular film, a film of mechanical support having one or more binders,fillers and dyes, wherein the substantially transparent layer, the layerof natural granules and the mechanical support layer form the multi-filmtop layer of the cladding panel.

In another embodiment of the method of manufacturing a cladding panel ofthe present invention, step (b) comprises disposing the natural granulesas clusters of different colors and sizes.

In another embodiment of the method of manufacturing a cladding panel ofthe present invention, the method comprises creating clusters of naturalgranules of different colors, laying the clusters on top of each otherto form a mass, and cutting the mass in slices, and wherein step (b)comprises disposing the slices onto the substantially transparent layer.

In another embodiment of the method of manufacturing a cladding panel ofthe present invention, the method further comprises filling gaps in thegranular film with a liquid mixture of substantially clear epoxy andcolor pigments to simulate veins.

In another embodiment of the method of manufacturing a cladding panel ofthe present invention, the films are layered or disposed on a base of amold's cavity, and wherein the base of the mold's cavity includesprotruding ribs having a top surface, and wherein the method furthercomprises disposing on the top surface of the ribs a composition thatsimulates grout.

In another embodiment of the method of manufacturing a cladding panel ofthe present invention, the method further comprises: (c) disposing afoaming binder on the film of mechanical support, and (d) disposing abase insulating layer onto the foaming binder thereby attaching the baseinsulating layer to the multi-film top layer.

In another embodiment the present invention provides for a kit of panelsfor covering a surface of a structure having a length x, wherein saidkit includes a first panel having a width equal to a, a second panelhaving a width equal to a+1, a third panel having a width a+2 and afourth panel having a width a+3, wherein x is greater or equal to threetimes a, and wherein x and a are positive integers.

BRIEF DESCRIPTION OF THE DRAWINGS

The following Figures illustrate various aspects and preferred andalternative embodiments of the invention.

FIG. 1A is perspective side view of a panel depicting the threedifferent layers according to one embodiment of the present invention.

FIG. 1B is a perspective front view of a panel depicting the externalmulti-films according to one embodiment of the present invention.

FIG. 2 is an exploded view of a panel depicting the parts of the moduleaccording the present invention.

FIG. 3 is a pattern diagram depicting the connection between the partsduring the installation of module on the support, according the presentinvention.

FIG. 4 is a pattern diagram depicting the connection between the panelsduring the installation on a support using an expansion joint system inaccordance to one aspect of the present invention.

FIG. 5 is a pattern diagram depicting the connection between the modularpanels during the installation on the support according the presentinvention.

FIG. 6A is a pattern diagram depicting the double interlock system onthe modular panels during the installation on the support according thepresent invention.

FIG. 6B is a pattern diagram depicting the double interlock system onthe modular panels during the installation on the support according thepresent invention.

FIGS. 7A-7E connection between modules of the present invention duringthe installation of a support using an expansion joint system inaccordance to one aspect of the present invention.

FIG. 8 is a flowchart of a method, according to one embodiment, ofproducing a panel of the present invention.

FIG. 9 is a flowchart of a method, according to one embodiment, ofproducing a panel of the present invention.

FIG. 10 is a perspective view of a panel according to another embodimentof the present invention including a mesh.

FIG. 11A is a perspective view of a panel according to anotherembodiment of the present invention depicting the top layer.

FIG. 11B is a perspective view of a panel according to anotherembodiment of the present invention depicting the top layer and a mesh.

FIG. 12 is a cross section from top to bottom of a mold to create apanel according to another embodiment of the present invention.

FIG. 13A, B are cross section from top to bottom of molds to create apanel according to another embodiment of the present invention.

DESCRIPTION OF THE INVENTION Definitions

Unless defined otherwise, all technical and scientific terms used hereinhave the same meaning as commonly understood by one of ordinary skill inthe art to which this invention belongs. Also, unless indicatedotherwise, except within the claims, the use of “or” includes “and” andvice versa. Non-limiting terms are not to be construed as limitingunless expressly stated or the context clearly indicates otherwise (forexample “including”, “having” and “comprising” typically indicate“including without limitation”). Singular forms including in the claimssuch as “a”, “an” and “the” include the plural reference unlessexpressly stated otherwise. All relevant references, including patents,patent applications, government publications, government regulations,and academic literature are hereinafter detailed and incorporated byreference in their entireties. The term “about” modifying any amountrefers to the variation in that amount encountered in real worldconditions of producing materials such as polymers or compositematerials, e.g., in the lab, pilot plant, production facility, orpanels. Whether or not modified by about, the amounts includeequivalents to those amounts. Any quantity stated herein and modified by“about” can also be employed in the present invention as the amount notmodified by about. In order to aid in the understanding and preparationof the within invention, the following illustrative, non-limiting,examples are provided.

In this document, references are made to layers, films and coats. It isunderstood that each layer, film and coat has an external or firstsurface, and an internal or second surface. When applied to a surface ora layer or a film or a coat, the terms “external” “top,” or “first”refer to the surface, layer, film or coat that would be facing or wouldbe exposed to the environment when the panel is attached to thesubstrate of a structure (i.e. away from the substrate of thestructure), and it includes the layer that can be viewed. The terms“internal” or “second” refer to the surface, layer, film or coat thatwould be facing or is adjacent to the substrate of the structure towhich the module or panel of the present invention is attached to.

The Panel

Preferred Mode for Carrying Out the Invention

Overview

The panel object of the present invention simulates genuine brick,stone, marble, slabs, tiles and so forth. The panel of the presentinvention may vary in shape, texture, color, and weight, depending onthe sought after style (tile, brick, stone, marble slab, and so forth)and the purpose (decoration of a wall, or create a countertop for avanity) chosen. The panel for the decoration of a building wall, forexample, could have the appearance of a finished assembled stone-walland generally will comprise an interlocking system for the assembly. Inone embodiment, the panel may simulate repeating brick or ceramic tilepatterns.

The dimensions of the panel, ranges, for example from side to side thepanel may range from about 1′ (1 foot or 30.48 cm) by 1′ to the width ofthe wall, but for convenience, is preferable a dimension that is easy tobe managed by one person, for example 4′ (˜121 cm) wide by 2′ (˜60.96cm) feet high.

The thickness of the panel may depend on the shape of the decoration andthe purpose of the installation that, for example, may also include thethermal insulation of the wall. In case one chooses to simulate aflag-stone and wants to reach a thermal resistance of 25R-value of thewall, the total thickness may range between 5″ (˜12.7 cm) and 8″ (˜20.32cm).

The manufacture of the external layer of the panel will depend on theplatform being simulated. For example, in the case of flag-stone, itwill be achieved by a combination of two different dust marble, pinkcorallo and White Carrara, while gray occhialino may be used for thegrout color.

The Panel

With reference to FIGS. 1A and 1B, a panel 100, according to oneembodiment of the present invention, may include a body 10, a top layer101 which provides a viewable surface, a base layer 103 which mayprovide structure and/or insulation, and a middle layer 102 which mayprovide the connection between the top layer 101 and the base layer 103.

The top layer 101 may include an external or first surface or top face134, an internal or second surface or bottom face 135 and sides 137extending from the first surface 134 to the second surface 135. In thecase of a rectangular panel, the external layer would include 4 sides,in a triangular panel, 3 sides, and so forth.

The top layer 101 may be made of one film/coat or of multiplefilms/coats (i.e. multi-film or multi-coat). The term “multi-film” or“multi-coat” as used herein, refer to an overlapping of several or manyfilms or coats as shown in FIG. 1B: an external substantiallytransparent film/coat 116, a film/coat of natural granules 117, and asupport film/coat 118. Although FIG. 1B illustrates 3 films, it shouldbe understood that less or more than 3 films are possible.

The external coat 116 of the top layer 101 may be a substantiallytransparent film 116. The external substantially transparent film 116may be made of a substantially transparent polymer, such as an acrylicresin, an unsaturated polyester resin, an epoxy resin, a melamine resin,a urethane resin, as described herein below. The external film 116 formsthe first surface 134 of the top layer 101.

The natural granule film 117 lies directly beneath the external film116. The natural granule film 117 may be made of inorganic fillers.Natural granules include one or more additives of an inorganic filler, across-linking agent, a cross-linking accelerator and a pigment, inaddition to the above described components. Specific kinds of theinorganic fillers above are not particularly limited. Examples of theseinorganic fillers may include one or more of calcium carbonate, silica,metal hydroxide, minerals and alumina. Specific diameter sizes of theinorganic fillers above are not particularly limited and any particlesizes ranging from 0.05 mm to 20 mm can be used.

The support film 118 may provide mechanical support to the external film116 and the granule film 117 as well as provide background color. Thesupport film 118 may be made of binders and/or fillers as describedherein below. The support film 118 forms the internal or second surfaceor bottom face 135 of the top layer 101.

The top layer 101 of the panel may simulate any genuine brick, stone,marble, granite, slab, tile desired and any desired pattern of bricks,stone, marble, granite, and tiles.

The middle layer 102 provides the connection between the top layer 101and the base layer 103. The middle layer 102 may be made of a foamingbinder such as polymer foam or cellular cement.

The base layer 103 is the layer that provides the insulation and/orstructure. The base layer 103 may be made of any suitable material thatprovides insulation and may also provide structure to the panel, such asextruded polystyrene, expanded polystyrene, polyisocyanurate,polyurethane, cementitious foam, cellular glass, vermiculite and soforth. The base layer 103 includes a first face that faces the secondsurface of the top layer 101, and a second face 108 that faces thesubstrate of the structure being covered. The second face 108 mayinclude one or more ventilation channels 105 as illustrated in FIG. 4 .The transversal cross section of the ventilation channels may take anysuitable shape, such as “T” or “V” shapes.

The panels 100 may take any suitable shape, such as rectangular,circular, triangular, square, and so forth.

The panels may include an interlocking system to interlock with otherpanels, or they may be devoid of interlocking system.

As illustrated in FIG. 10 , the panel may also include a mesh 780connected to the second surface of the support film 118, which may bemade of metal or a fiber that is non-combustible. This optional meshwill reinforce the structure of the layer 101 and will function as aplace for mechanical support of the panel if the insulation layer 103 isnot required or to prevent the detachment of the panel from the support(wall), if, in case of fire, the layer 103 the primary place ofmechanical support of the panel, will melt.

The top layer 101 provides the looks of the panel, the middle layer 102and the base layer 103 may be made of the same or different materials.The base layer 103 may provide insulation and/or structure, while middlelayer 102 provides the connection between the top layer 101 and base 103layer. As illustrated in the embodiment of FIGS. 11A-B, the middle layerand the base layer may not be necessary if, for example, insulation isnot required. In FIGS. 11A-B the panel 1100 consists of only the toplayer 1101 (FIG. 11A) or the top layer 1101 and a mesh 1178. In FIGS.11A-B the top, multi-film layer comprises the substantially transparentcoat 1160, the granular coat 1170 and the background color coat 1180. InFIG. 11B, the mesh 1178 is connected to the second surface of thebackground color coat 1180.

Double Interlock System

In the embodiment illustrated in FIGS. 1A and 1B, the perimeter of amodular panel 100 may include interlocking systems. In the case of amodular panel 100, at least two sides of the external layer 101 mayinclude first and second connecting profiles or attachment mechanisms 15a,b. The first connecting profile or attachment mechanism 15 a isdisposed on a side of the panel 100 to interlock with a correspondingsecond connecting profile or attachment mechanism 15 b on an adjacentpanel and retained.

The connecting profiles 15 a,b of the modular panel 100 may includeflanges 115 and pockets 16 formed about the sides of the body 10. Theflanges 115 and pockets 16 are adapted to fit together with matingflanges and pockets of an adjacent panel.

With reference to FIG. 6 , in the case of modular panels 100 a,b with aninsulating layer 103, the bottom surface of pocket 16 may be formed bythe insulating layer (see FIG. 6A). When the modular panel 100 a isattached to a substrate, the panel may be secured by screws 700 throughthe bottom surface of pocket 16 to the substrate. When the flange of aneighboring panel 100 b interlocks with the pocket 16 of the panel 100 ascrewed to the substrate, the flange of the neighboring panel 100 b willhide the screw 700. Both module 100 a,bs, will have a double interlockand will hide the screws 700 that will attach one of the said modules100 a to the substrate, and hold in place the next one 100 b (see FIG.6A and FIG. 6B).

Interlock with Expansion Joint System

In another embodiment, illustrated in FIG. 4 and FIG. 7A-E, theperimeter of the top layer 101 may include interlocking flanges 115 toconnect to adjacent panels 100 a,b as explained above and pockets 16.The profile of the base layer 103 may include a dovetail shape 122. Kindof usable shape in preparing said dovetail shapes are not particularlylimited. Examples of such shape, which are usable herein, may includean, “T”, “V” shape (see FIG. 4 and FIG. 7 ). In this case, the pocket 16lacks a bottom surface, as the base layer 103 does not extend. Aconnector 106 is provided for each direction and having a dovetail shapecomplementary to the dove tail shape of the base layer 103. Theconnector includes a first face 107. As such, the connector 106 may bepositioned next to the base layer 103 as shown in FIGS. 7A-C, and thefirst face 107 of the connector 106 will serve as the bottom surface ofthe pocket 16. Once secured, through screws 700 for example, to asubstrate (floor, wall or pitch of the roof and so forth), will lock themodule 100 a to the previously mentioned support (see FIG. 4 ). The nextmodule 100 b, joining to said connector 106 with its interlocks, willcover any joints (screws 700) on the connector 700 and engage onto withthe module 100 a already locked to the support and leaving a gap 701between the interlocks (see FIGS. 7D-E). Said connector 106, includes anexposed face 107 and in contact with said interlocks of externalmulti-films layer of said module. Said exposed face 107, may, in oneembodiment, be covered with the same compound used to create grout asdescribed herein below. Said connector 106 acts both as an expansionjoint and joint the interlocks of the modules 100 a,b connected,covering said gap 701 and maintaining the continuity of said grout ofthe modules 100 a,b.

Method of Producing the Panels

The methods for producing the panels of the present invention will benow described with reference to FIGS. 1A, 1B, 2, 3, 4, 5, 6A, 6B, 8 and9 .

FIG. 8 shows a general flow chart of the method in accordance to oneembodiment: (a) forming a substantially transparent coat (801); (b)dispose one, two or three of: a composition comprising natural granulesand/or color onto the substantially transparent coat (802 a), and/orclusters of compositions comprising natural granules and/or color ontothe substantially transparent coat (802 b), and/or slices of a mass ofclusters comprising natural granules and/or color onto the substantiallytransparent coat (802 c); (c) dispose a support and/or background layeronto the composition of natural granules and/or color (803); (d) disposea binder onto the layer of support and/or background color (804); and(e) dispose a base layer onto the binder (805).

The present invention includes, in one embodiment, a method to producethe panel 100 of the present invention. The method for the production ofsaid panel 100 may be divided into phases, which will produce at leastthree layers of which the panel (or modules) is/are comprised: a topmulti-films layer 101, a middle layer 102, and a base layer 103. Anoptional step of adding grout (806) is also depicted between steps 803and 804.

The method to produce a panel of the present invention includes the useof a mold 1200. With reference of FIG. 12 , the mold 1200 comprises acontinuous side wall 1201 forming the perimeter of the mold 1200 and abase 1205. The interior surfaces of the walls and the base 1205 form themold's cavity 1202. The interior surface of the base forms the cavity'sfloor.

The floor of the mold cavity 1202 will create the shape or silhouette ofthe external multi-film layer 101 of said panel. Said mold 1200 can bemade in different material: semi-hard, soft or hard, perennial or notperennial. Said floor of the mold's cavity 1202 includes a shape orsilhouette. Said shape may include interlocks 115 and pockets 16 on thetop multi-films layer 101 of said panel that will match and connectmultiple modules (see FIG. 5 ). Said mold 1200 can be closed with acounter mold or opened, without a counter mold. Said mold includes acase to hold one or more molds. If it is intended to produce theabove-mentioned system, the molds may need to be created at least fourmolds, that are able to produce modules having dimensions according tosaid criterion and interlocks 115, on two or more sides distributedasymmetrically (see FIG. 1A). The mold 1200 may be made of any suitablematerials (metal, plastic silicon, wax etc.). The interior bottomsurface of the mold 1200 will replicate the negative shape of the wantedconfiguration of the panel. For example, in the case of a flag-stone orbrick, the bottom surface of the mold 1200 may present depressions, andtextures for the correspondent stones or bricks and ribs 1203 separatingthe depressions for forming the groves in between the flag stones.

First Phase: The Top Layer

The top, multi-film or multi-coat layer 101 may be created with at leastthree different methods.

In FIGS. 8 and 9 , steps 802 and 902 illustrate three options: 802 a/902a, 802 b/902 b and 802 c/902 c respectively. Each option represents thethree methods described herein below. It should be understood thatanyone or any combination of these three options may be used. Forexample, one may dispose cluster of compositions and slices of a mass ofclusters.

The first two steps are common to all three methods:

-   -   1. Spread a release-agent on the interior surfaces of a mold        (surfaces within the cavity of the mold), to form a        release-agent coat.    -   2. Spread onto the release-agent coat, a coat of a substantially        transparent polymer to form the substantially transparent coat        116 of the top layer 101 (see 801/901).

The use of a release agent facilitates the removal of the panels fromthe mold. However, it should be understood that this step may not benecessary. The release agent may include different compositions likeliquid, gel, and dust. The shape, the form and the texture of theexternal surface 134 of the top layer 101 of the module 100, will beinfluenced by the release agent.

Kind of usable substantially transparent polymer in preparing saidsubstantially transparent coat 116 are not particularly limited.Examples of such substantially transparent polymer, which are usableherein, may include one or more of an acrylic resin, an unsaturatedpolyester resin, an epoxy resin and a melamine resin, a urethane resin.Specific kinds of said acrylic resin are not particularly limited. Forexample, a polymer of one or more acrylic monomers of methyl (meth)acrylate, ethyl (meth)acrylate, butyl (meth)acrylate, 2-ethylhexyl(meth)acrylate, benzyl (meth)acrylate and glycidyl (meth)acrylate may beused. Kinds of said unsaturated polyester resins are also notparticularly limited. For example, a polyester resin having an acidvalue of 5 to 40 and a weight average molecular weight of 1,000 to5,000, which is prepared through a condensation reaction of anunsaturated dibasic acid or a mixture of said dibasic acid and saturateddibasic acid with a polyhydric alcohol, may be used. At this time, theprocess for preparing said polyester resin is not particularly limited.For example, it may be prepared by a method which comprises a step ofmixing said dibasic acid and the like with said polyhydric alcohol in aspecific ratio (for example, moles of alcoholic hydroxide group/moles ofcarboxylic group=0.8 to 1.2), subjecting said mixture to a condensationreaction at a temperature of about 140 to about 250° C. under an inertgas flow such as carbon dioxide gas and/or nitrogen gas with removingresulting water and slowly increasing the temperature depending ondegree of proceeding the reaction. Examples of unsaturated dibasic acidsor saturated dibasic acids as used above may include maleic anhydride,citraconic acid, fumaric acid, itaconic acid, phthalic acid, phthalicanhydride, isophthalic acid, terephthalic acid, succinic acid, adipicacid, sebasic acid and/or tetrahydrophthalic acid, and the like.Examples of polyhydric alcohols may include ethylene glycol, diethyleneglycol, triethylene glycol, propylene glycol, dipropylene glycol,tripropylene glycol, polypropylene glycol, 1,3-butylene glycol,hydrogenated bisphenol A, trimethylol propane monoarylether, neopentylglycol, 2,2,4-trimethyl-1,3-pentanediol and/or glycerine, and the like.If necessary, said polyester resin may further comprise a monobasic acidsuch as acrylic acid, propionic acid and/or benzoic acid; or polybasicacid such as trimellitic acid and/or benzene tetracarboxylic acid. Inaddition, kinds of usable epoxy resins are also not particularlylimited. For example, a bifunctional or multifunctional epoxy resin maybe used. Examples of said bifunctional or multifunctional epoxy resinsmay include one or more of a bisphenol A epoxy resin, a bisphenol Sepoxy resin, a tetraphenyl ethane epoxy resin and a phenol novolac epoxyresin.

(i) First Method of Making the Top Multi-Film Layer 101

-   -   1. Spread a release-agent on the interior bottom surface of the        mold, to form a release-agent coat.    -   2. Spread onto the release-agent coat, a coat of a substantially        transparent polymer to form the substantially transparent coat        116 (801/901).    -   3. Overlay or dispose a composition comprising natural granules        and/or color onto the substantially transparent polymer coat        116, preferably before it hardens, to form a film or coat of        granules and/or color 117 (802 a/902 a).

The granular/color layer may be made of desired color pigments, and mayinclude natural granules to provide a more genuine look. The color layermay pre-made.

Natural granules that may be used in this method or any of the methodsdescribed below includes one or more additives of an inorganic filler, across-linking agent, a cross-linking accelerator and a pigment, inaddition to the above described components. Specific kinds of theinorganic fillers above are not particularly limited. Examples of theseinorganic fillers may include one or more of calcium carbonate, silicaand silica derivatives, metal hydroxide, minerals, glass and alumina.Specific sizes of the inorganic fillers are not particularly limited andit can be use any sizes ranging from 0.05 mm to 20 mm in diameter. Forgranular look, bigger sizes, for a smoother look, smaller sizes. Thenuance-color can be laid, using different colors, layer by layer orstone by stone: one may lay the color layer in a non-uniform way, orstone by stone so as to imitate the original brick, marble and so forth.

The following are the ingredients that can be used to prepare differentcolors that may be used:

Nuance-Color for flag-stone: Pink corallo marble, white Carrara, grayocchialino dust (size 0.7-1.2 mm)

Nuance-Color for brick: black ebano marble dust (size 0.7-1.2 mm)

Base-color for flag-stone: a mix in ratio in weight of 1 to 10 in dustof pink corallo and white Carrara (size 0.7-1.2 mm)

Base-color for brick: red Verona marble dust (size 0.7-1.2 mm)

(ii) Second Method of Making the Top Multi-Film Layer 101

Materials:

Prepare granular mixtures in ratio of 1 to 6 of clear epoxy and marbledust of one, two, three or more different color, like Pink corallomarble, white Carrara, gray occhialino dust (diameter size 0.7-1.2 mm).Create granular clusters of one or different colors and sizes with themixtures.

Optionally, prepare a liquid mixture of a clear epoxy and colorpigments.

Steps:

-   -   1. Spread a release-agent on the interior bottom surface of the        mold, to form a release-agent coat.    -   2. Spread onto the release-agent coat, a coat of a substantially        transparent polymer to form the substantially transparent coat        116 (801/901).    -   3. Fill the mold with the granular clusters in a uniform or        no-uniform way (802 b/902 b). If a liquid mixture is provided,        the liquid mixture may be interposed in the gaps between        granular clusters (903). This liquid mixture may be used to form        the veins of marble or granite. The granular clusters with or        without the liquids will form the granular coat 117.

This second method may be used to replicate granite (if the diameter ofthe clusters is in range of 1 mm to 20 mm in diameter) and marble (ifthe diameter of the clusters is sized above 20 mm in diameter).

An optional polishing phase with a final coat of acrylic resin willlighten up the nature of the vein.

(iii) Third Method of Making the Top Multi-Film Layer 101

This method may be suitable for creating slabs, which can be used tocreate table-tops, countertops, tomb stones, and so forth. This thirdmethod may give a similar result as the above method 2 without a need toadd the polishing phase with the final coat of acrylic resin.

Materials:

Prepare one, two, three or more mixtures in ratio of 1 to 6 of clearepoxy and marble dust of one or different colors, like Pink corallomarble, white Carrara, gray occhialino dust (size 0.7-1.2 mm). Createclusters of different color and sizes with the mixtures.

Optionally prepare a liquid mixture of clear epoxy and pigments color

3. Create a granular mass, for example by laying the clusters of one ordifferent colors one on each other, in a no-uniform way, optionallyinterposing the liquid mixture in the gaps between the clusters.

Steps:

-   -   1. Spread a release-agent on the interior bottom surface of the        mold, to form a release-agent coat.    -   2. Spread onto the release-agent coat, a coat of a substantially        transparent polymer to form the substantially transparent coat        116 (801/901).    -   4. Cut the mass of clusters in slices. If liquid mixture is        used, then every slice will show veins marble like or granite        like (it will depend on the diameter size of the clusters).    -   5. Position the slices onto the substantially clear coat in the        mold, in a uniform or a no-uniform way to form the granular coat        117 (802 c/902 c).

Method 3 can be used to replicate granite (if the diameter of theclusters is in range of 1 mm to 20 mm) and marble (if the diameter ofthe clusters is above 20 mm in diameter).

In option polishing phase with a final coat of acrylic resin willlighten up the nature of the vein.

The final step, common to all of methods 1-3 is to overlap a film orcoat of mechanical support and/or of background color, preferably,before the granular coat hardens, to form the support layer 118, whichmay provide background color (803/904). This support layer 118 may be amixture, preferably 1 to 3 in weight, of a clear epoxy and a base color.

The film 118 of mechanical support and/or of background color may bemade of a single component or a mixture of components. Said componentsmay include binders and fillers. Said binders include, in measure ofweight of 15% to 35%, of a substantially transparent polymer. Kinds ofusable substantially transparent polymer in preparing said binders arenot particularly limited. Examples of such substantially transparentpolymer, which are usable herein, may include one or more of an acrylicresin, an unsaturated polyester resin, an epoxy resin and a melamineresin, a urethane resin. Specific kinds of said acrylic resin are notparticularly limited. For example, a polymer of one or more acrylicmonomers of methyl (meth) acrylate, ethyl (meth) acrylate, butyl (meth)acrylate, 2-ethylhexyl (meth) acrylate, benzyl (meth) acrylate andglycidyl (meth) acrylate may be used. Kinds of said unsaturatedpolyester resins are also not particularly limited. For example, apolyester resin having an acid value of 5 to 40 and a weight averagemolecular weight of 1,000 to 5,000, which is prepared through acondensation reaction of an unsaturated dibasic acid or a mixture ofsaid dibasic acid and saturated dibasic acid with a polyhydric alcohol,may be used. At this time, the process for preparing said polyesterresin is not particularly limited. For example, it may be prepared by amethod which comprises a step of mixing said dibasic acid and the likewith said polyhydric alcohol in a specific ratio (for example, moles ofalcoholic hydroxide group/moles of carboxylic group=0.8 to 1.2),subjecting said mixture to a condensation reaction at a temperature ofabout 140° C. to about 250° C. Under an inert gas flow such as carbondioxide gas and/or nitrogen gas with removing resulting water and slowlyincreasing the temperature depending on degree of proceeding thereaction. Examples of unsaturated dibasic acids or saturated dibasicacids as used above may include maleic anhydride, citraconic acid,fumaric acid, itaconic acid, phthalic acid, phthalic anhydride,isophthalic acid, terephthalic acid, succinic acid, adipic acid, sebasicacid and/or tetrahydrophthalic acid, and the like. Examples ofpolyhydric alcohols may include ethylene glycol, diethylene glycol,triethylene glycol, propylene glycol, dipropylene glycol, tripropyleneglycol, polypropylene glycol, 1,3-butylene glycol, hydrogenatedbisphenol A, trimethylol propane monoarylether, neopentyl glycol,2,2,4-trimethyl-1,3-pentanediol and/or glycerine, and the like. Ifnecessary, said polyester resin may further comprise a monobasic acidsuch as acrylic acid, propionic acid and/or benzoic acid; or polybasicacid such as trimellitic acid and/or benzene tetracarboxylic acid. Inaddition, kinds of usable epoxy resins above are also not particularlylimited. For example, a bifunctional or multifunctional epoxy resin maybe used. Examples of said bifunctional or multifunctional epoxy resinsmay include one or more of a bisphenol A epoxy resin, a bisphenol Sepoxy resin, a tetraphenyl ethane epoxy resin and a phenol novolac epoxyresin. Furthermore said film of mechanical support and of backgroundcolor include, a foamed material and/or natural granules. Examples ofsaid foamed material include foamed polymers and foamed cementousmaterials with inorganic fillers. Specific kinds of cementous materialsare not particularly limited. Examples of these cementous materials mayinclude one or more of cellular concrete Gypsum (GRG) and so on.Moreover, said fillers of the above mixture, includes natural granulesin measure of weight of 65% to 85%. Natural granules include one or moreadditives of an inorganic filler, a cross-linking agent, a cross-linkingaccelerator and a pigment, in addition to the above describedcomponents. Specific kinds of the inorganic fillers are not particularlylimited and they can be used in any particle sizes ranging from 0.05 mmto 20 mm in diameter. Examples of these inorganic fillers may includeone or more of calcium carbonate, silica and silica derivatives, metalhydroxide, minerals, alumina and fire retardant additive, flameretardant additives or incombustible additive.

Grout

If grout is desired in between the bricks or marble stones, to have thecolor of said grout independently from the rest of the stone, one mayproceed as follow:

To recreate grout, a mold, such as the mold 1200 depicted in FIG. 12 ,may be provided with ribs 1203 extending from the cavity's floor. Thetop surface of the ribs 1203 protruding from the floor of the mold'scavity 1202 may be cleaned or scraped from the materials that were laidin the previous steps (methods 1-3). Alternatively, the top surface ofthe ribs 1203 may be masked, and the mask removed thereby leaving aclean surface on the ribs 1203. The materials/compositions used tocreate said mask are not particularly limited. Examples of thesematerials may include one or more metals, papers, plastic, wood, paintand composites.

1. Clean the ribs 1203 of the mold 1200 where the shape represent thegrout.

Specific processes of how to clean said mold where the shape representthe grout are not particularly limited. Examples of these processes mayinclude scraping out the excess of the materials above described tocreate said external multi-films layer in the present method.

2. Overlay a composition comprising the color of the preferred grout onthe top surface of the ribs 1203 to create said external multi-filmslayer in the present method (806/907). For example, a mix in ratio 1 to4 in weight of clear epoxy with the grout (grey occhialino marble dust(size 0.7-1.2 mm)) and lay it on the ribs 1203; allow the layers tocombine and leave it until it cures.

Second Phase: The Base Layer 103 The second phase relates to thepreparation of the base layer 103. Kind of usable material in preparingsaid base layer are not particularly limited. Examples of suchmaterials, which are usable herein, may include one or more of aninsulating and a structuring material. Specific kinds of said insulatingmaterial are not particularly limited. For example extruded polystyrene,(XPS). Expanded polystyrene (EPS) Molded expanded polystyrene (MEPS),polyisocyanurate, polyisocyanurate insulating material in structuralinsulated panels (sips) polyurethane, cementitious foam, cellular glass,vermiculite, may be used. This base layer 103 includes a shape orsilhouette. The base layer 103 includes a first surface or face that isadjacent to the inner or middle layer, and a second surface or face 108and functions as back to the module, which is in contact with thesupport (for example wall, roof, etc.). Said silhouette includes anumber of ventilation channels 105. Said ventilation channels 105 have ashape. (See FIG. 2 ). Kinds of usable shape in preparing saidventilation channels are not particularly limited. Examples of suchshape of ventilation channels, which are usable herein, may include aninterlocking dovetail, “T”, “V” shape 105 may be used (see FIG. 4 ). Theface 108 of layer 103 faces the structure. Said channels 105 may beconfigured to receive components 104 capable of merging to said channelsincluding an interlocking clips 104 (see FIGS. 2 and 3 ). Kinds ofusable material in preparing said components are not particularlylimited. Examples of such material like, polymeric structural materialand metal may be used. Said components 104 may be independently securedto the support of the structure, such as a house. The panels may then besecured to the components 104 by inserting or sliding the components 104into the channels 105 which will lock the module to the same support(see FIG. 3 ). Said silhouette of said base layer 103, comprises adifferent combination of profiles. The present invention includesmultiple systems to install said module to the support (for examplewall, roof, etc.) According to the system chosen, the base layer maypossibly have different profiles of said silhouette.

Third Phase: Assembly of the Base Layer 103 to the Top Layer 101

The third phase includes the assembly of the base layer 103 alreadyprepared, to the top multi-films layer 101, through the creation of themiddle layer 102 (see FIG. 1 ). The assembly includes a layering offoaming or non-foaming binder directly on the second surface of themulti-films layer 101 while is still in the mold (804, 905). Kind ofusable foaming binder to assemble the above layers are not particularlylimited. Examples of such foaming binder, which are usable herein, mayinclude Polymer foam, cellular cement. The base layer 103 is thendisposed onto the binder (805, 906).

To speed up the production, it is possible to use the middle layer 102as a counter-mold for the curing time of the external multi-films layer,as illustrated in FIG. 13B. In order to proceed in this manner, a secondmold 1300 that has the shape of the middle layer 102 and fits within thefirst mold 1200 can be used. The foaming or non-foaming binder thatmakes the middle layer is poured into this second mold 1300. The base103 is then placed on top of the middle layer 102 before is cured. Afterthe middle layer 102 is cured and bound to the base layer 103, themiddle layer 102 with the bound base layer 103 is demolded from mold1300 (as shown by the arrow in FIG. 13A) and placed on the top themulti-films layer (i.e. on top of the layer 118) during the multi-filmlayer 101 curing time, as shown in FIG. 13B. The first mold 1200 isthereby closed with the middle layer 102 bound to the base 103, and theexternal multi-films layer becomes a binder to the middle layer 102.

Another option instead of a binder is to increase the volume of thegrout or the background layer. This may be achieved by preparing acomposite in a ratio (in weight) of about 1 of clear epoxy to 4 of amixture, the mixture having a ratio of about 1 to 1 in weight of grout(grey occhialino marble dust (diameter size 0.7-1.2 mm)) or backgroundcolor (marble dust (size 0.7-1.2 mm)), with micro balloon of glass (sizebetween 0.3-3 mm) or silica fume, and lay this composite on the granularfilm 117, and cover the composite with the base of polystyrene 103 andclose firmly the lid of the mold until it cures.

Furthermore, to speed up the curing time of the different layers,another optional phase may be to expose the different layers to atemperature in the range of about 50 C.° to about 150 C.°. This heat maybe applied by inserting the mold in an oven, or may be applied to thebottom of the mold (with a heating element, heating lamp, heated air andso forth), or to the top of the mold (with a heating element, heatinglamp, heated air, and so forth), or to the inside of the mold (heatedair, heating lamp, infrared rays, and so forth), and/or of the molditself and/or the surrounding area during the process.

With reference to FIG. 10 , in the preparation of the layer 101, a mesh(metal mesh or fiber fabric mesh such as carbon, glass or Kevlar™ or anyother non-combustible material) could be added and immersed in thebackground layer (or in the grout if one is provided) while is still wet(not cured yet) in measure to exceed from the surface 137, an adequatebraces or brackets that can be screwed to the support during theinstallation process.

As such, in one embodiment, the present invention provides for acladding panel for covering a substrate, the cladding panel comprising:

(a) a body comprising a top face which provides a viewable surface and abottom face, at least a first edge and a second edge with a firstconnecting profile and a second connecting profile respectively, and amesh,

the first connecting profile and the second connecting profile beingcomplementarily shaped in such a way that adjacent cladding panels arecoupled to one another via said first connecting profile and the secondconnecting profile,

each of the first connecting profile and the second connecting profilecomprising a pocket and a flange, the pocket of the first connectingprofile being shaped for receiving the flange of the second connectingprofile,

(b) a base layer for attachment of the cladding panel to the substrate,and

(c) a middle layer disposed between the bottom face of the body and thebase layer,

wherein the mesh and the base layer overhang the pocket of the firstconnecting profile and the pocket of the second connecting profile suchas forming a viewable bottom surface of the pocket of the firstconnecting profile and of the pocket of the second connecting profile,the viewable bottom surface being configured to receive fasteners and toact as a double interlock and sealant when adjacent cladding panels arecoupled to one another via said first connecting profile and the secondconnecting profile.

In one embodiment of the cladding panel, the base layer comprising aninsulating material and the middle layer comprising a foaming binder,the base layer having a first face connected to the middle layer and asecond face for connecting to the substrate, the second face of the baselayer having one or more ventilation channels.

In another embodiment of the cladding panel, the base layer has sideshaving a dovetail shape designed for receiving a connector element.

In another embodiment of the cladding panel, the viewable surface of thetop face includes groves that simulate grout.

In another embodiment of the cladding panel, the viewable surfaceincludes artificial depressions and textures that replicate depressionsand textures of a natural stone.

In another embodiment of the cladding panel, the body comprises amultifilm layer of overlapping films arranged in this order from the topface to the bottom face: an external transparent film, a film ofgranules and a support film that provides mechanical support to thepanel and forms the bottom face of the body, wherein the externaltransparent film comprises a transparent polymer, the film of granulescomprises dust filler, a cross-linking agent, a cross-linkingaccelerator and a color pigment, and the support film comprises binders,fillers and dyes, and wherein the mesh is immersed in the support film.

Kit or System

A kit or system according to one embodiment of the present inventionincludes a number of at least four modules of the present invention withsubstantial coordinated sizing under a criterion disclosed in thepresent invention. The use of said criterion is not particularly limitedto said insulation system. It may include one or more of constructionpaneling and module, structure, furniture and so on. Said criterion isdescribed as follows:

Given a positive integer number, the sum of a multiple of said givennumber with a positive multiple for each of the three followingconsecutive integers, is capable to suit any number positive integer,greater than or equal to three times the given number. According to thiscriterion, assuming 12 as the given number, the three following numberswill be 13, 14, and 15. The sum of the positive multiples of these fournumbers will be able to reach any chosen positive integer number greaterthan 36 (3 times 12).

On Table 1 random positive integer numbers are reached using the abovecriterion. In the top row, “a” represents the given number (12), “x”represents the random number and n is a number used to minimize themultiple of the given number (12); in this table, “n” was chosen to beequal to 4. The numbers “a+1”, “a+2”, and “a+3”, represent respectivelythe consecutive numbers of 12 (13, 14, and 15). On said table 1, theabove numbers “a” “a+1”, “a+2”, and “a+3”, represent possible differentwidths of the modules while “x” represent possible different widths ofthe surface where the modules will be installed. All the widths areexpressed in inches. As it can be noticed, the criterion fulfills anyrandom number (widths of surfaces) equal or greater than three times thegiven number; in this case, all widths greater than 36 inches.

TABLE 1 a a + 1 a + 2 a + 3 n(a) x >= 3a amount of amount of amount ofamount of amount of Random 12-inch 13-inch 14-inch 15-inch 48-inch sizein modules modules modules modules modules inches 4 19 964 3 14 711 3 12 4 271 2 1 1 12 627 1 1 18 891 3 1 15 777 7 17 914 3 11 567 2 1 38 18658 1 127 2 2038 97854 1 4 3 213 3 2 9 498 2 1 37 1 2 111 3 3 14 753 8 1125 9 502 1 1 8 411 2 32 1566 2 2 2 154 3 4 231 5 1 16 853 2 7 366 1 3 3199 1 3 17 871 4 17 872 3 1 17 873 2 2 17 874

The following examples are intended to illustrate, and not limit theembodiments disclosed herein.

EXAMPLES

Description of the Mold

The mold made by any materials (metal, plastic silicon, wax, etc.) willreplicate the negative shape of the wanted figure. In case of the aboveflag-stone or brick, the mold will present depressions, and texture forthe correspondent stones or bricks and ribs for the groves in between.

Example 1

Preparation

1. Create a case with a lid to contain the shape and measure of themold.

2. Put the mold in the case and live the lid opened.

3. Spread a release-agent on the surface of the mold

4. Nuance-Color for flag-stone: prepare, Pink corallo marble, whiteCarrara, gray occhialino dust (size 0.7-1.2 mm)

Nuance-Color for brick: prepare black ebano marble dust (size 0.7-1.2mm)

5. Base-color for flag-stone: prepare, a mix in ratio in weight of 1 to10 in dust of pink corallo and white Carrara (size 0.7-1.2 mm)

Base-color for brick: prepare red Verona marble dust (size 0.7-1.2 mm)

6. Spread in the mold a clear coat of epoxy.

7. While the coat is still wet, lay a non-uniform layer of Nuance-Coloron the mold.

The Nuance-Color can be laid, using different colors, layer by layer orstone by stone.

8. Prepare a mix in ratio 1 to 3 in weight of clear epoxy withbase-color and lay it on the mold.

9. Clean in different ways (scraping, use mask) the ribs of the mold.

10. Prepare a mix in ratio 1 to 4 in weight of clear epoxy with thegrout (grey occhialino marble dust (size 0.7-1.2 mm)) and lay it on theribs; allow the layers to combine and leave it until it cures.

11. Prepare a sheet of polystyrene in measure to cover the mold.

12. Prepare a solution of foaming glue/binder, such as liquidpolyurethane, in measure that when react, the foam produced will fillcompletely the mold.

13. Cover the mold with the sheet of polystyrene and close firmly thelid of the case on it until it cures.

After step 9 a preferred option is:

Prepare a mix in ratio 1 to 4 in weight of clear epoxy with a mix inratio 1 to 1 in weight of grout (grey occhialino marble dust (size0.7-1.2 mm)) with micro balloon of glass (size between 0.3-3 mm) orsilica fume and lay it on the mold filling it completely and cover itwith the sheet of polystyrene and close firmly the lid of the case on ituntil it cures.

Example 2

After release agent and clear coat, instead of color layer of Example 1,prepare

1. Create a case with a lid to contain the shape and measure of themold.

2. Put the mold in the case and live the lid opened.

3. Spread a release-agent on the surface of the mold

4. Spread in the mold a clear coat of epoxy.

5. Prepare three or more mixtures in ratio of 1 to 6 of clear epoxy andmarble dust of three or more different color, like Pink corallo marble,white Carrara, gray occhialino dust (size 0.7-1.2 mm).

6. Prepare a liquid mixture of clear epoxy and pigments color

7. Create clusters of different color and sizes with the mixtures

8. Fill the depressions in the mold with the above clusters in anon-uniform way, interposing the liquid mixture in the gaps betweenthem.

9. Clean in different ways (scraping, use mask) the ribs of the mold.

10. Prepare a mix in ratio 1 to 4 in weight of clear epoxy with a mix inratio 1 to 1 in weight of grout (grey occhialino marble dust (size0.7-1.2 mm)) with micro balloon of glass (size between 0.3-3 mm) orsilica fume and lay it on the mold filling it completely and cover itwith the sheet of polystyrene and close firmly the lid of the case on ituntil it cures.

The solution of Example 2 can replicate granite (if the diameter of theclusters are in range of 1 mm to 20 mm) and marble (if the diameter ofthe clusters are bigger without limit).

Optionally, a polishing phase with a final coat of acrylic resin willlighten up the nature of the vein.

Example 3

The present method will give a similar result of the above Example 2without the polishing phase with the final coat of acrylic resin.

Preparation

1. Create a case with a lid to contain the shape and measure of themold.

2. Put the mold in the case and live the lid opened.

3. Spread a release-agent on the surface of the mold

4. Spread in the mold a clear coat of epoxy.

5. Prepare three or more mixtures in ratio of 1 to 6 of clear epoxy andmarble dust of three or more different color, like Pink corallo marble,white Carrara, gray occhialino dust (size 0.7-1.2 mm).

6. Prepare a liquid mixture of clear epoxy and pigments color

7. Create clusters of different color and sizes with the mixtures

8. Create a bigger mass on a table a side, laying the clusters one oneach other, in a no-uniform way, interposing the liquid mixture in thegap between them.

9. Cut in slice the mass

10. Every slice will show veins marble like or granite like (it willdepend on the size of the clusters) that will be positioned into thedepressions in the mold, in a no-uniform way

11. Clean in different ways (scraping, use mask) the ribs of the mold.

12. Prepare a mix in ratio 1 to 4 in weight of clear epoxy with a mix inratio 1 to 1 in weight of grout (grey occhialino marble dust (size0.7-1.2 mm)) with micro balloon of glass (size between 0.3-3 mm) orsilica fume and lay it on the mold filling it completely and cover itwith the sheet of polystyrene and close firmly the lid of the case on ituntil it cures.

Example 3 will replicate granite (if the diameter of the clusters are inrange of lmm to 20 mm) and marble (if the diameter of the clusters arebigger without limit).

In option polishing phase with a final coat of acrylic resin willlighten up the nature of the vein.

Through the embodiments that are illustrated and described, thecurrently contemplated best mode of making and using the invention isdescribed. Without further elaboration, it is believed that one ofordinary skill in the art can, based on the description presentedherein, utilize the present invention to the full extent. Allpublications cited herein are incorporated by reference.

Although the description above contains many specificities, these shouldnot be construed as limiting the scope of the invention, but as merelyproviding illustrations of some of the presently embodiments of thisinvention.

What is claimed is:
 1. A panel for covering a substrate, the panelcomprising: a body comprising a top face which provides a viewablesurface, and a bottom face opposite to the top face, a first connectingprofile and a second connecting profile, and a mesh, the firstconnecting profile and the second connecting profile beingcomplementarily shaped in such a way that adjacent panels are coupled toone another via the first connecting profile and the second connectingprofile, each of the first connecting profile and the second connectingprofile comprising a pocket and a flange, the pocket of the firstconnecting profile being shaped for receiving the flange of the secondconnecting profile and the pocket of the second connecting profile beingshaped for receiving the flange of the first connecting profile, whereinthe mesh overhangs both the pocket of the first connecting profile andthe pocket of the second connecting profile, said mesh overhangsconfigured for attachment of the panel to the substrate.
 2. The panel ofclaim 1, wherein the panel further comprises a base layer connected tothe bottom face of the body for attachment of the panel to thesubstrate, wherein the mesh and the base layer overhang both the pocketof the first connecting profile and the pocket of the second connectingprofile.
 3. The panel of claim 2, wherein the base layer includes afirst face connected to the bottom face of the body, a second face forconnecting to the substrate and lateral walls extending from the firstface to the second face, the second face of the base layer having one ormore ventilation channels extending from one lateral edge to anotherlateral edge, and the lateral walls of the base layer having a dovetailshape designed for receiving a connector element.
 4. The panel of claim1, wherein the viewable surface of the top face includes groves thatsimulate grout.
 5. The panel of claim 1, wherein the viewable surfaceincludes artificial depressions and textures that replicate depressionsand textures of a natural stone.
 6. The panel of claim 1, wherein thebody comprises a multifilm layer of overlapping films: an externaltransparent film, a film of granules and a support film that providesmechanical support to the panel and forms the bottom face of the body,wherein the external transparent film comprises a transparent polymer,the film of granules comprises dust filler, a cross-linking agent, across-linking accelerator and a color pigment, and the support filmcomprises binders, fillers and dyes, and wherein the mesh is immersed inthe support film.
 7. The panel of claim 1, wherein the substrate is awall, a floor or a roof.